Rare-earth high-entropy aluminate-toughened-zirconate dual-phase composite ceramics for advanced thermal barrier coatings

Superb toughening is achieved by incorporating a secondary ferroelastic phase in high-entropy rare-earth zirconate 5RE2Zr2O7 (HZ). Here, we report an enhancement of 64% in fracture toughness through the addition of 30mol% high-entropy rare-earth aluminate 5REAlO3 (HA) to the HZ matrix (30HA). The aforementioned rare-earth elements RE are La, Sm, Eu, Gd, and Yb. The present dual-phase composite ceramic 30HA has a large fracture toughness of 2.77 ± 0.14 MPa m1/2, along with excellent high-temperature phase stability, resulting in good usage for potential thermal barrier coating applications. Particularly, the fracture toughness of the dual-phase composite ceramics at first increases to a maximum and then drops suddenly, as the mole fraction of HA increases from 0 to 50%. A clear definition of fitting parameters and their physical significance is provided for a better interpretation of the experimental data. The present toughening mechanism sheds light on microstructure engineering in high-entropy ceramics for excellent mechanical properties.